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47

Disassembly/Inspection and Service

24 690 34 Rev. D

KohlerEngines.com

After cleaning, check 

fl

 atness of cylinder head and 

corresponding top surface of crankcase, using a surface 

plate or piece of glass and feeler gauge. Maximum 

allowable out of 

fl

 atness is:  

0.076 mm (0.003 in.) for 80 mm bores;
0.1 mm (0.003 in.) for 83 mm bore.
Carefully inspect valve mechanism parts. Inspect valve 

springs and related hardware for excessive wear or 

distortion. Check valves and valve seat area or inserts 

for evidence of deep pitting, cracks, or distortion. Check 

clearance of valve stems in guides. 
Hard starting or loss of power accompanied by high 

fuel consumption may be symptoms of faulty valves. 

Although these symptoms could also be attributed to 

worn rings, remove and check valves 

fi

 rst. After removal, 

clean valve heads, faces, and stems with a power wire 

brush. 
Then, carefully inspect each valve for defects such as a 

warped head, excessive corrosion, or a worn stem end. 

Replace valves found to be in bad condition.

Valve Guides

If a valve guide is worn beyond speci

fi

 cations, it will not 

guide valve in a straight line. This may result in burnt 

valve faces or seats, loss of compression, and excessive 

oil consumption.
To check valve guide-to-valve stem clearance, 

thoroughly clean valve guide and, using a split-ball 

gauge, measure inside diameter of guide. Then, using 

an outside micrometer, measure diameter of valve stem 

at several points on stem where it moves in valve guide. 

Use largest stem diameter to calculate clearance by 

subtracting stem diameter from guide diameter. If intake 

clearance exceeds 0.038/0.076 mm (0.0015/0.0030 

in.) or exhaust clearance exceeds 0.050/0.088 mm 

(0.0020/0.0035 in.), determine whether valve stem or 

guide is responsible for excessive clearance.
Maximum (I.D.) wear on intake valve guide is 7.134 mm 

(0.2809 in.) while 7.159 mm (0.2819 in.) is maximum 

allowed on exhaust guide. Guides are not removable but 

can be reamed 0.25 mm (0.010 in.) oversize. Valves with 

0.25 mm oversize stems must then be used.
If guides are within limits but valve stems are worn 

beyond limits, install new valves.

Valve Seat Inserts

Hardened steel alloy intake and exhaust valve seat 

inserts are press 

fi

 tted into cylinder head. Inserts are 

not replaceable but can be reconditioned if not too badly 

pitted or distorted. If cracked or badly warped, cylinder 

head should be replaced.
Recondition valve seat inserts following instructions 

provided with valve seat cutter being used. Final cut 

should be made with an 89° cutter as speci

fi

 ed for 

valve seat angle. Cutting proper 45° valve face angle 

as speci

fi

 ed, and proper valve seat angle (44.5°, half of 

full 89° angle), will achieve desired 0.5° (1.0° full cut) 

interference angle where maximum pressure occurs on 

outside diameters of valve face and seat.

Lapping Valves

NOTE:  Exhaust valves that are black in color cannot be 

ground and do not require lapping.

Reground or new valves must be lapped in, to provide 

proper 

fi

 t. Use a hand valve grinder with a suction cup 

for 

fi

 nal lapping. Lightly coat valve face with a 

fi

 ne grade 

of grinding compound, then rotate valve on its seat with 

grinder. Continue grinding until a smooth surface is 

obtained on seat and on valve face. Thoroughly clean 

cylinder head in soap and hot water to remove all traces 

of grinding compound. After drying cylinder head, apply 

a light coating of SAE 10 oil to prevent rusting.

Intake Valve Stem Seal

These engines use valve stem seals on intake valves. 

Always use a new seal when valves are removed 

from cylinder head. Seals should also be replaced if 

deteriorated or damaged in any way. Never reuse an old 

seal.

Hydraulic Lifters Inspection

Check base surface of hydraulic lifters for wear or 

damage. If lifters need to be replaced, apply a liberal 

coating of Kohler lubricant to base of each new lifter 

before it is installed.

Bleeding Lifters

To prevent a possible bent push rod or broken rocker 

arm, it is important to bleed any excess oil out of lifters 

before they are installed.
1.  Cut a 50-75 mm (2-3 in.) piece from end of an old 

push rod and chuck it in a drill press.

2.  Lay a rag or shop towel on table of drill press and 

place lifter, open end up, on towel.

3.  Lower chucked push rod until it contacts plunger in 

lifter. Slowly pump plunger 2 or 3 times to force oil 

out of feed hole in side of lifter.

Содержание Command PRO CH682

Страница 1: ...cation System 31 Electrical System 38 Starter System 42 Disassembly Inspection and Service 56 Reassembly IMPORTANT Read all safety precautions and instructions carefully before operating equipment Ref...

Страница 2: ...contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead...

Страница 3: ...nually Change oil Lubrication System Remove cooling shrouds and clean cooling areas Air Cleaner Intake Check oil cooler fins clean as necessary if equipped Lubrication System Every 200 Hours Change oi...

Страница 4: ...proved and should NOT be used effects of old stale or contaminated fuel are not warrantable Fuel must meet these requirements Clean fresh unleaded gasoline Octane rating of 87 R M 2 or higher Research...

Страница 5: ...T 2 67 50 2 657 MUFFLERMOUNTING BOSSES OILFILL OILDIPSTICK 113 08 4 452 95 50 3 760 36 50 1 437 622 41 24 504 5 8 18UNF2B INCH 38 10 1 500 155 58 6 125 152 08 5 987 OILFILTER 5 50 217 PILOT FUELPUMP 1...

Страница 6: ...in lb into new holes 4 0 N m 35 in lb into used holes M6 Fasteners 10 7 N m 95 in lb into new holes 7 3 N m 65 in lb into used holes Carburetor Intake Manifold and Air Cleaner Intake Manifold Mounting...

Страница 7: ...eel Fan Fastener 9 9 N m 88 in lb Flywheel Retaining Screw 66 4 N m 49 ft lb Fuel Pump Pulse Fastener 2 3 N m 20 in lb Governor Lever Nut 6 8 N m 60 in lb Ignition Spark Plug 27 N m 20 ft lb Module Fa...

Страница 8: ...d Play 0 076 0 127 mm 0 0030 0 0050 in Running Clearance 0 025 0 063 mm 0 0010 0 0025 in Bore I D New Max Wear Limit 20 000 20 025 mm 0 7874 0 7884 in 20 038 mm 0 7889 in Bearing Surface O D New Max W...

Страница 9: ...6116 in 40 84 mm 1 608 in 0 022 mm 0 0009 in 0 025 mm 0 0010 in Closure Plate End Main Bearing Journal O D New O D Max Wear Limit Max Taper Max Out of Round 40 913 40 935 mm 1 6107 1 6116 in 40 84 mm...

Страница 10: ...sion Ring to Groove Side Clearance 0 030 0 070 mm 0 001 0 0026 in Middle Compression Ring to Groove Side Clearance 00 030 0 070 mm 0 001 0 0026 in Oil Control Ring to Groove Side Clearance 0 060 0 190...

Страница 11: ...lve Guide Running Clearance 0 050 0 088 mm 0 0020 0 0035 in Intake Valve Guide I D New Max Wear Limit 7 038 7 058 mm 0 2771 0 2779 in 7 134 mm 0 2809 in Exhaust Valve Guide I D New Max Wear Limit 7 03...

Страница 12: ...English Fastener Torque Recommendations for Standard Applications Bolts Screws Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Ti...

Страница 13: ...logy Inc DTI 731 03 Dealer Tool Kit Domestic Complete kit of Kohler required tools Components of 25 761 39 S Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Rectifier Regulator T...

Страница 14: ...d brushes Individual component available Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82411 SE Tools KLR 82416 Triad OHC Timing Tool Set For holding cam gears and crankshaft in timed positio...

Страница 15: ...ing gear teeth Bosses will lock tool and flywheel in position for loosening tightening or removing with a puller A spanner wrench to lift rocker arms or turn crankshaft may be made out of an old junk...

Страница 16: ...e to check simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some general common causes of engine troubles are lis...

Страница 17: ...indications of improper fit and seal Check air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into engine A dirty or clogged e...

Страница 18: ...s closed 2 Start engine and run no load high speed 3 Open clamp and note water level in tube Level in engine side should be a minimum of 10 2 cm 4 in above level in open side If level in engine side i...

Страница 19: ...t Install a 3 8 in breaker bar into hole slot of holding tool so it is perpendicular to both holding tool and crankshaft PTO If flywheel end is more accessible use a breaker bar and socket on flywheel...

Страница 20: ...Ensure both ends of breather tube are properly connected AIR COOLING WARNING Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Never operate engine with heat...

Страница 21: ...nnected to fitting on crankcase 4 Attach new fuel pump using screws Torque screws to 2 3 N m 20 in lb 5 Reconnect fuel lines to inlet and outlet fittings and secure with clamps Mechanical Pump Mechani...

Страница 22: ...gine is hot or running Walbro Two Barrel Carburetor Components A B C D E F G H I J K L M N O P Q R S T U V W X A Carburetor Body Subassembly B Vacuum Hose C Float Valve Inlet Needle D Float E Bowl Gas...

Страница 23: ...uns rough or stalls at idle speed Low idle speed improperly adjusted Adjust low idle speed tab Engine runs rich indicated by black sooty exhaust smoke misfiring loss of speed and power governor huntin...

Страница 24: ...in through fixed and metered idle progression holes As throttle plate opens further vacuum signal becomes great enough so main circuit begins to work Main high speed At high speeds loads engine operat...

Страница 25: ...pen end wrench and carefully remove nozzle tubes from bowl Note and mark jets by location for proper reassembly Main jets and main nozzles may be size side specific Main jets are pressed into bottom o...

Страница 26: ...held in between body mounting legs insert new pivot pin through float hinge and into opposite hole 20 Invert carburetor body as shown and measure dimension between top of float and top of gasket floa...

Страница 27: ...tion tension of governor spring holds throttle plate open When engine is operating governor gear assembly is rotating Force applied by regulating pin against cross shaft tends to close throttle plate...

Страница 28: ...rnor lever If speed surging occurs with a change in engine load governor is set too sensitive If a big drop in speed occurs when normal load is applied governor should be set for greater sensitivity a...

Страница 29: ...L AND FILTER Change oil while engine is warm 1 Clean area around oil fill cap dipstick drain plug oil drain valve a Remove drain plug and oil fill cap dipstick Allow oil to drain completely or b Open...

Страница 30: ...ivalent to threads of switch 2 Install switch into tapped hole in breather cover 3 Torque switch to 4 5 N m 40 in lb Testing Compressed air a pressure regulator pressure gauge and a continuity tester...

Страница 31: ...e feeler gauge Adjust gap to 0 76 mm 0 03 in 2 Install plug into cylinder head 3 Torque plug to 27 N m 20 ft lb Inspection Inspect each spark plug as it is removed from cylinder head Deposits on tip a...

Страница 32: ...C 200 cca minimum 0 F to 32 F 18 C to 0 C 250 cca minimum 5 F to 0 F 21 C to 18 C 300 cca minimum 10 F 23 C or below 400 cca minimum If battery charge is insufficient to turn over engine recharge batt...

Страница 33: ...KohlerEngines com Electrical System W C H D B I A AD E G F F A K B L J N M P O R Q S T U V R W R X Y Z V AA AB AC AF AI AJ AL AE AK AH AG R T V V AM AN AO AH Wiring Diagram 15 20 25 Amp Regulated Batt...

Страница 34: ...Starter AJ Ground AK Key Switch Ground AL Rectifier AM Blue Red AN Battery Positive AO Battery Negative Electronic Ignition Systems Tests NOTE Ignition tester must be used to test ignition on these e...

Страница 35: ...wing guidelines to avoid damage to electrical system and components Make sure battery polarity is correct A negative ground system is used Disconnect rectifier regulator plug and or wiring harness plu...

Страница 36: ...g tester into proper AC outlet power for tester being used Turn on power switch POWER light should be illuminated and 1 of 4 status lights may be on as well This does not represent condition of part 6...

Страница 37: ...regulator steps 2 and 3 2 Remove connector from rectifier regulator With engine running at 3600 RPM measure AC voltage across stator leads using an AC voltmeter Condition Conclusion Voltage is 28 volt...

Страница 38: ...ssible Cause Conclusion Starter does not energize Battery Check specific gravity of battery If low recharge or replace battery as necessary Wiring Clean corroded connections and tighten loose connecti...

Страница 39: ...and plunger spring from drive end cap If solenoid was mounted with external Torx head screws plunger is part of solenoid unhook plunger pin from drive lever Remove gasket from recess in housing 4 Remo...

Страница 40: ...ines Install drive pinion onto armature shaft 2 Install and assemble stop collar retainer assembly a Install stop collar down onto armature shaft with counter bore recess up b Install a new retainer i...

Страница 41: ...to solenoid for any time over what is necessary for performing each of individual tests Internal damage to solenoid may occur Disconnect all leads from solenoid including positive brush lead attached...

Страница 42: ...sket D Carburetor E Air Cleaner Gasket F Outer Baffle G Breather Tube H Oil Sentry I Breather Cover J Breather Gasket K Inner Baffle L Breather Reed WARNING Before working on engine or equipment disab...

Страница 43: ...ged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow manufacturer s instructions and...

Страница 44: ...screw and washer securing rectifier regulator ground lead or grounding strap 8 Remove remaining screws and detach blower housing 9 Disconnect plug from key switch in blower housing if engine is equipp...

Страница 45: ...s NOTE Cylinder heads are retained using either screws or nuts and washers on studs Do not interchange or mix components as cylinder heads may have different machining unique to each fastening method...

Страница 46: ...alve stem seals intake valve only 4 Repeat above procedure for other cylinder head Do not interchange parts from one cylinder head to other Inspection and Service Valve Details EXHAUST VALVE INTAKE VA...

Страница 47: ...ms are worn beyond limits install new valves Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press fitted into cylinder head Inserts are not replaceable but can be re...

Страница 48: ...ng backing plates and stator wire bracket if equipped Remove backing plates and stator wire bracket 2 Remove screws and stator Remove Ignition Modules 1 Disconnect lead from each ignition module 2 Rot...

Страница 49: ...er O ring Style B X Oil Pump Assembly Style B Y Oil Pick Up Tube Style B Remove Closure Plate Assembly 1 Remove screws securing closure plate to crankcase 2 Locate splitting tabs cast into perimeter o...

Страница 50: ...aft Oil Pump Assembly Style A Oil Pump Style A Torque Sequence 1 2 Oil pump is mounted inside closure plate If service is required refer to Disassembly Inspection and Reassembly Disassembly 1 Remove s...

Страница 51: ...t into corresponding recess in closure plate Apply consistent downward pressure to oil pump cover compressing oil pressure relief spring and start screws Secure oil pump by torquing screws in no speci...

Страница 52: ...re severe than detonation damage Preignition is caused by a hot spot in combustion chamber from sources such as glowing carbon deposits blocked cooling fins an improperly seated valve or wrong spark p...

Страница 53: ...r crankcase Do not replace bearings unless they show signs of damage or are out of running clearance specifications If crankshaft turns easily and noiselessly and there is no evidence of scoring groov...

Страница 54: ...tches or nicks Inspect main bearing if equipped for wear or damage Replace crankcase using a miniblock or short block as required Check cylinder bore wall for scoring In severe cases unburned fuel can...

Страница 55: ...taper and size Use an inside micrometer telescoping gauge or bore gauge to take measurements These measurements should be taken at 3 locations in cylinder at top middle and bottom There are 2 measure...

Страница 56: ...small amount of oil to threads of critical fasteners before assembly unless a sealant or Loctite is specified or preapplied Make sure all traces of any cleaner are removed before engine is assembled...

Страница 57: ...Lubricate cylinder bore piston and piston rings with engine oil Compress rings of piston 1 using a piston ring compressor 3 Lubricate crankshaft journals and connecting rod bearing surfaces with engi...

Страница 58: ...RTV sealant and secure it with only 2 or 3 fasteners at this time Use a dial indicator to check crankshaft end play End play should be 0 070 1 190 mm 0 0028 0 0468 in Shim spacers are available in 3 c...

Страница 59: ...eaned and prepared Install a new O ring in closure plate 2 Check to make sure there are no nicks or burrs on sealing surfaces of closure plate or crankcase 3 Apply a 1 5 mm 1 16 in bead of sealant to...

Страница 60: ...all screw and washer 4 Use a flywheel strap wrench or holding tool to hold flywheel Torque screw securing flywheel to crankshaft to 66 4 N m 49 ft lb Install Flywheel Fan NOTE Position ears located at...

Страница 61: ...ttom surface of each lifter Lubricate hydraulic lifters and lifter bores in crankcase with engine oil 3 Note mark or tag identifying hydraulic lifters as either intake or exhaust and cylinder 1 or cyl...

Страница 62: ...est to lifters must have an exposed height of 75 mm 2 15 16 in Studs furthest from lifters must have an exposed height of 69 mm 2 3 4 in c Remove nuts and repeat procedure as required 4 Install cylind...

Страница 63: ...crews to 4 0 6 2 N m 35 55 in lb 7 Repeat steps 4 through 6 for other ignition module 8 Rotate flywheel back and forth checking for clearance between magnet and ignition modules Make sure magnet does...

Страница 64: ...Air Cleaner Gasket F Outer Baffle G Breather Tube H Oil Sentry I Breather Cover J Breather Gasket K Inner Baffle L Breather Reed M Filter N Electric Starter O Lifting Bracket P Fixed Guard Q Blower Ho...

Страница 65: ...s are routed out through proper offsets or notches so they will not be pinched between blower housing and baffles 4 If rectifier regulator was not removed attach ground wire or metal grounding bracket...

Страница 66: ...and are open 2 Apply Loctite 242 to shorter inner set of threads of any removed studs 3 Assemble carburetor gasket and carburetor to intake manifold and start any removed studs Use two flange nuts lo...

Страница 67: ...o breather cover Torque to 4 5 N m 40 in lb 2 Connect wire lead green to Oil Sentry terminal Install Control Panel if equipped 1 Install panel to blower housing 2 Connect throttle control cable or sha...

Страница 68: ...and torqued to specifications to prevent oil leakage 1 Install oil drain plug s Torque plug s to 13 6 N m 10 ft lb If oil drain valve is used make sure valve body is closed and cap is on 2 Place new f...

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Страница 72: ...8 85612 22193 3 1P24 690 34 2015 by Kohler Co All rights reserved 72 24 690 34 Rev D KohlerEngines com...

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